Condensation of aldehydes with aromatics or thiophenes in the presence of glauconite



Patented Jan. 17, 1950 CONDENSATION F ALDEHYDES WITH ABO- MATICS 0R THIOPHENES IN THE PRES- ENCE OF GLAUUONITE Howard D. Hartough. Pltman, and John J. Sardella, Woodbury, N. 1.. assign ore to Socony- Vacuum Oil Company, Incorporated, a corporation of New York No Drawing. Application April 20, 1946, Serial No. 665.315

(Cl. 2M7) 6 Claims.

The present invention relates to the condensation of hydrocarbons with carbonyl compounds and, more particularly, to the condensation of aromatic hydrocarbons with carbonyl compounds in the presence of a cheap, readily separable solid catalyst.

The condensation of aromatic hydrocarbons with various carbonyl compounds, especially aldehydes, in the presence of various catalysts has long been practiced. In the prior art there are many descriptions oi methods for carrying out the condensation of aromatic compounds with carbonyl compounds employing sulfuric acid, metal chlorides, such as ferric chloride, aluminum chloride and zinc chloride, and acetic acid solutions of such metal chlorides. More recently it has been shown that the hydrogen halides, and more particularly hydrogen fluoride, may be used to accelerate this condensation. In other words, the catalysts of the prior art are either acids or salts having an acid reaction. It now has been discovered that in contrasts to the acidic catalysts of the prior art a natural amphoteric material can be used as a cheap, readily separable catalyst for this reaction. Accordingly, it is an object of the present invention to provide a novel catalyst for condensations involving carbonyl compounds and aromatic hydrocarbons, phenols and/or heterocyclic compounds such as thicphene. It is another object of the present invention to provide a means for pretreating the novel catalyst to improve the yields. It is a further object of the present invention to provide a means for producing viscous oils or subresinous materials and resins or resinous materials. Other objects and advantages will become apparent from the following description.

In general, the present process involves the use of natural material classified as a marl which heretofore has been used primarily as a water softener. Commercially it is known as "greensand, while its technical designation is glauconlte. Glauconlte can be used as a condensation agent for condensing active carbonyl compounds and aromatic hydrocarbons, phenols, heterocyclic compounds and the like after drying at 100 to 550 degrees centigrade or after being activated and dried at elevated temperatures. Glauconite or greensand is a naturally occur- 2 ring deposit found in various localities. Its exact composition is dependent upon the area in which it is found. In general, the larger portion of the glauconite comprises the oxides of aluminum, silicon, iron, potassium and magnesium or calcium. The composition of giauconite usually falls within the limits set forth in the following:

Per cent composition S10: 40.00to 53.61 A: 6.62 to 13.00 FeaOs 15.16 to 23.43 FeO 1.32 to 10.17 MgO 0.95 to 2.97 CuO 0.57 to 1.9! Nat-0 0.42 to 2.16 K20 3.49 to 9.54 H20 4.93 to 10.32

Giauccnite has been characterized by geologists as having the approximate formula,

KMgFes-SlsOxrliHaO In general, the glauconite, aromatic hydrocarbon or mixture of hydrocarbons containing aromatic hydrocarbons or phenolic material or heterocyclic compounds or mixtures of the aforesaid materials, and an active carbonyl compound are mixed, charged into a suitable pressure resistant container and the contents heated to about to about 500 degrees Fahrenheit for reaction times of about 0.5 hour to about 16 to about 24 hours and at autogenous pressures. The mixture is then cooled (to room temperature, for example) and the giauconite separated by any suitable means, for example, by filtration.

The catalyst or condensation agent (glauconite) is then washed with a solvent for the condensation product, for example, benzene or the hydrocarbon charge stock. The washings are combined with the liquid reaction product (filtrate when separated by nitration) and subjected to distillation under vacuum. The washing liquid and unreacted charge stock separated, a cut of viscous oil or subresinous amterial obtained and resinous material recovered as a still residue.

Suitable charging stocks include aromatic hydrocarbons per se, aromatic petroleum stocks containing at least 25 per cent monoor polynuclear, alkylated or non-alkylated, aromatic hydrocarbons in admixture with paraflinic and naphthenic hydrocarbons, phenols or mixtures of phenols or mixtures of hydrocarbons containing phenols, heterocyclic hydrocarbons such as thiophene, thiophene derivatives having at least one replaceable nuclear hydrogen including alkyl thiophenes, aikoxy thiophenes, halogenated thicphenes, etc. or mixtures of the store-enumerated charge stocks.

The glauconite or greensand may be used in the as mined" condition after removal of surface water by drying at 100 degrees centigrade or after activation. Activation may be accomplished bytreating the mar] with mineral acid such as sulfuric acid or hydrogen halide or phosphoric acid in aqueous solution at about 80 to about 100 degrees centigrade for several hours. For example, about 600 parts by weight of glauconite are suspended in about 1800 parts by weight of distilled water containing about 120 parts by weight of concentrated sulfuric acid. That is, the glauconite is treated with an about 1.4 N solution of acid. The suspension is heated and agitated at 80 degrees centigrade for about 3 to about 8 hours, preferably about hours. The liquid is separated from the treated glauconite as by decantation, the glauconite washed until the washings are free from acid and the glauconite dried at elevated temperatures of say 100 to about 500 degrees centigrade (212 to 930 degrees Fahrenheit) and preferably at temperatures of about 200 to about 275 degrees centigrade (400 to 530 degrees Fahrenheit).

The giauconite can also be activated by drying at elevated temperatures of about 200 to about 300 degrees centigrade (400 to 575 degrees Fahrenheit), preferably about 225 to 275 degrees centigrade (435 to 530 degrees Fahrenheit) without acid pretreatment.

Suitable aromatic hydrocarbons for use as charging stocks include benzene, toluene, xylenes, mono-, di-, triand tetraalkyi benzenes, naphthalene, monoand polyalkyl naphthalenes, anthracenes, monoand polyalkyl anthracenes and other aromatic hydrocarbons and mixtures of aromatic hydrocarbons, parafllns and naphthenes known to the art as aromatic petroleum stocks. For example, aromatic petroleum stocks containing polyalkyl benzenes and known to the art as Sovasol" #75 may be used. An inspection of "Sovasol" #75 (75 per cent overhead) is the following:

60F, SPBClfiG gravlty m o.8348

0 A. P. I. gravity 38.0

Italian bromine index -01) Per cent aromatics "60431.8

A. B. T. M. distillation: I. I. B. P --auo lli cent -314 per cent per cent "844 Per cent recovery 99 Per cent residue 1 Other aromatic petroleum stocks such as SovasoP' #74 constituted primarily (80 per cent) 0! xylenes and aromatic petroleum stocks 1, 2 and 3 constituted primarily of naphthalene. monomethyl and dimethyl naphthalenes; polyalkyl (2-5 aikyl, methyl and/or ethyl) naphthalenes; and alkylated trinuclear aromatic hydrocarbons (mostly anthracenes and phenanthracenes) and alkyiated diphenyl, respectively, are suitable charge stocks.

The novel method for producing subresinous and resinous bodies is readily illustrated by the reaction between aromatic petroleum stocks and formaldehyde. It is to be understood that the following examples are typical of reaction conditions employed and products obtained when using any of the suitable charging stocks and any of the suitable active carbonyl compounds.

Aromatic petroleum stock, glauconite and trioxymethylene (paratormaldehyde) were introduced into a pressure resistant container in the amounts indicated in the table. The temperature was raised to about 150 degrees centigrade (302 degrees Fahrenheit) in about 15 minutes while stirring the reaction mixture. The reaction mixture was agitated and heated at about 150 degrees centigrade for an additional 30 minutes, during which period the pressure rose to about 80 to about 100 pounds per square inch gauge. Thereafter the reactor was cooled rapidly to room temperature. The reactor was discharged, the glauconite removed by filtration and washed with benzene or, in some instances, with the aromatic stock. The filtrate and washings were distilled in vacuum and two distiilates recovered. One distillate comprised unreacted charge stock and washing liquid and the other comprised the viscous oil or subresinous product. The resin was obtained as a still residue.

The yields in the table are calculated assuming that the aromatic hydrocarbons condense with methylene bridges. Thus, from dimethyl naphthalene it is believed that H CH C is obtained and from trimethyl benzenes (CHI) E OH is obtained. as the initial condensation products or, in other words, the condensation products are subresinous to resinous products having the formula I! [ii-c-]n' Condensation Aunt. parts by wt.

its

50 I) I) 100 it!) 100 I) and Condensation Amt Dried 2250 0. 482 F.). Dried 640 0. 004 F)" arl Dried 6 Xctiva te d dried Homerstown M Retreat dried at temperatures above about 000 degrees Fahrenheit is inferior as a condensation agent 0 parts bywt.

2a DIMQIWO.

to glauconite dried at lower temperatures or to activated glauconite.

Run No.

Aromatics, parts by wt.

mwmmmmm used mmmmmmm m m Redn stock, parts by wt.

w antennae mmm u nnuananmnu mm a mum e siest w unannounced mm mm uoawumuu mn y a m t m 111 3 3. m amammnnmanm 0 mm 02mm wwmommonaaa Per Out Amt. Aromatics onhuman Charge Stock Aromatic Petroleum Stock ID. Aromatic Petroleum Charge Stock Aromatics Predominantly Naphthalene and methyl naphthalen 446-507 Monoand dlmethyl naphthalene. 300-315 Trimethyl benzenes.

Bolling Range Run No.

with or without subetituent groups and a is an integer.

l.. Aromatic Petroleum Run No.

III an 845678911 Aromatic Petroleum Stock Dried Dried to resinous products does not vary to any great It will be observed that the ratio of sub-resinous m ummmmuw H m .m m a e 11 n mmm mmmmmmmmmmw w a BRW m m umuuumm w m m M M, mmmm-lfio 1 ammmmmm W scheme The viscous oils and resins listed in the table had the following boiling ranges Run No.

\ greensand dried at about 470 to about 575 de- The data in the table indicate (runs 2, 9, 10) great Fahrenheit. that a mole ratio of CHzO to aromatic hydro- The foregoing can be summarized as follows: carbon of 0.3 or greater the yield of resin stock The novel method prius reacting a conis not eflected but that at mole ratios less than densible materml selected the group sisting of aromatic hydrocarbons. phenolic com- 0.3, say 0.2, the yield of resin stock (sub resinous 05 pounds, heterocyclic compounds and mixtures plus resinous material) drops oi! rapidly. Fur of non condensme h d y rocarbons and any one thermore, increasing the amount of active caror more of the foregoing condensible hydrobonyl compound (formaldehyde) does not affect carbons with an active carbon compound such the Yield 3 and as the aldehydes (alicyclic or carbocycllc), for increasing the amount of catalyst markedly example, formaldehyde. acetaldehyde, benzaldeaffect the Yield resin 3 and hyde, etc. at temperatures of about 150 to about Howe the re ous treat n of t catalyst 500 degrees Fahrenheit at autogenous pressures does affe h yield of in Stock a the p for a reaction time of about 0.5 hour to about portion of sub-resinous to resinous material. 24 hours in the presence of glauconite, preferably Thus, considering runs 4, 5, 6 and I, glauconite activated by drying at a temperature of about 7 470 to about 575 degrees Fahrenheit. Ai'ter "D ration of the reaction products from the glauconite, the reaction products are distilled under vacuum to remove unreacted reactants and wash fluid and to obtain sub-resinous material of the natureo! viscousoilasadistillateandastill residue of the nature 01 a thermoplastic resin.

We claim:

1. A method for producing sub-resinous and resinous materials which comprises reacting aromatic hydrocarbons with iormaldehyde in the absence of a substantial amount of water, in the presence 01' alauconite, at temperatures of about 150 to about 500 decrees Fahrenheit and at autogenous pressures.

2. A method as set forth and described in claim 1 in which the slauconite is activated by being prevlousLv subjected to temperatures or about 470 to 575 F.

9. A method for producing sub-resinous and no resinous materials which comprises reactins thicphene with formaldehyde in the absence of a substantial amount of water, in the presence oi. glauconite, at temperatures of about 150 to about 500 degrees Fahrenheit and at autogenous g5 5. A method for producins sub-resinous and resinous materials which comprises reacting a cyclic compound having an active nuclear hydrogen selected from the group consist-in: o! aromatic hydrocarbons and thiophenes with formaldehyde in the presence of aiauconite at temperatures of about 150 to about 500 degrees Fahrenheit at autoaenous pressures and in the absence of a substantial amount of water.

0. A method as set forth and described in claim 5 in which the slauconite is activated by being previously subjected to temperatures oi about 470 to about 575 degrees Fahrenheit.

HOWARD D. HARTOUGH. JOHN J. BARDEILA.

REFERENCES CITED The following references are 0! record in the the of this patent:

UNITED STAT PATENTB Number Name Date 1,970,204 Stockton Aug. 14, 1994 2,200,763 Anderson et al May 14, 1940 2,217,014 Grosse et a1 Oct. 8, 1940 2,432,991 Hartough et a1 Dec. 23, 1947 OTHER REFERENCES Nuttins. pages 80-82, Reilner and Natl. Gasoa line Min, Mar. 1933, vol. 12, No. 9. 

1. A METHOD FOR PRODUCING SUB-RESINOUS AND RESINOUS MATERIALS WHICH COMPRISES REACTING AROMATIC HYDROCARBONS WITH FORMALDEHYDE IN THE ABSENCE OF A SUBSTANTIAL AMOUNT OF WATER, IN THE PRSENCE OF GLAUCONITE, AT TEMPERATURES OF ABOUT 150 TO ABOUT 500 DEGREES FAHRENHEIT AND AT AUTOGENOUS PRESSURES. 